Disposable pull-on pant

ABSTRACT

Pull-on garments provided with a continuous belt in the front region and the back region to distribute the forces generated during use in order to better fit the pull-on garment on the wearer. In a preferred embodiment, the pull-on garment comprises a chassis layer comprising a continuous sheet that defines a front region, a back region, and a crotch region; a first belt layer joined to the chassis layer in the front region; a second belt layer joined to the chassis layer in the back region; elastic panel members positioned between the belt layers and the chassis layers which laminate is mechanically stretched to form elastically extensible stretch laminates in both the front region and the back region in the side panels; and seams joining the front region to the back region so as to form the leg openings and waist openings. The continuous chassis layer and belt layers thus form the continuous belt of the pull-on garment. Because the belt layers extended continuously laterally across the waist region and do not cover the entire crotch region, and because the chassis layer is thus exposed in the crotch region, the pull-on garment has a unique aesthetic feature which consumers perceive as providing a cloth-like feel in the waist but the containment characteristics in the crotch.

This application is a continuation of U.S. patent application Ser. No.08/713,054 filed on Sep. 12, 1996, now U.S. Pat. No. 5,836,932, issuedNov. 17, 1998; which is a continuation of U.S. patent application Ser.No. 08/415,816 filed on Apr. 3, 1995, now U.S. Pat. No. 5,569,234 issuedOct. 29, 1996.

FIELD OF THE INVENTION

The present invention relates to disposable pull-on garments which aredonned by inserting the wearer's legs into the leg openings and slidingthe garment up into position about the lower torso. Examples of suchdisposable pull-on garments include disposable underwear, pull-ondiapers, training pants, and disposable panties for menstrual use. Thepresent invention more particularly relates to unitary disposableabsorbent pull-on garments such as pull-on diapers, training pants,incontinent pull-on briefs, and the like, which provide improved wearercomfort, increased leakage protection, and sustained dynamic fit.

BACKGROUND OF THE INVENTION

Infants and other incontinent individuals wear disposable absorbentarticles as diapers to receive and contain urine and other bodyexudates. Absorbent garments having fixed sides (e.g., training pants orpull-on diapers) have become popular for use on children able to walkand often who are toilet training. In order to contain body exudates swell as to fit a wide variety of body shapes and sizes, these pants mustfit snugly about the waist and legs of the wearer without drooping,sagging or sliding down from its position on the torso as well asfitting larger wearers without causing irritation to the skin due to theproduct being too tight. Thus, the pant must have elastic extensibilityin the waist and legs with the elastic features providing a high degreeof stretch.

Many training pants and pull-on diapers use conventional elasticelements secured in an elastically contractible condition in the waistand leg openings. Typically, in order to insure full elastic fit aboutthe leg and the waist such as is provided with durable undergarments,the leg openings and waist opening are encircled with elasticized bandsof rubber or other materials positioned along the curve of the opening.These pants are typically characterized as “balloon syle” pants becauseof the contraction caused by the elasticized bands in specific zones ofthe product while the remaining material tends to blouse. Examples ofsuch training pants are disclosed in U.S. Pat. No. 5,171,239 to Igaue,et al. on Dec. 15, 1992 and U.S. Pat. No. 4,610,681 to Strohbeen, et al.on Sep. 9, 1986. Although these pants will allow fit of various waistand leg sizes due to the fact that the contractive elastic openings willexpand to accommodate various size wearers, these products still fit alimited range of fit sizes because the elastic elements are incontraction and do not have a high degree of stretch. The narrow elasticbands used in the waist opening and the leg openings also tend toconcentrate the “fitment” forces in a narrow zone of the wearer's bodyleading to increased incidence of skin marking of the wearer. Further,the sides and remainder of the products are typically not elasticallyextensible thereby reducing the fit.

In order to solve this deficiency in balloon-style pants, somemanufacturers have positioned elastic strands across the entire frontand back regions of the product. For example, WO 93/17648 published onSep. 16, 1993, discloses a pant-type diaper in which the front and/orthe rear parts are elastically contractible and the ends of theabsorbent core are disposed in these regions. These additional elasticstrands act to contract the entire front and back waist parts of thepant including the end areas of the absorbent core. This allows greaterexpansion of the product in the waist region but causes the absorbentcore to be gathered and bunch at the waist opening. This gathering andbunching results in a higher risk of leakage at the waist since channelsare created along the absorbent core that allows body exudates to wickor flow out of the waist. This gathering of the absorbent core alsoaffects the appearance of the product in that the product does notappear as aesthetically pleasing as the balloon style pants.

Another type training pant is shown in U.S. Pat. No. 4,940,464 issued toVan Gompel, et al. on Jul. 10, 1990, wherein a pant-like garment isformed by attaching discrete stretchable members to the side edges ofthe main body of the garment. This stretchable member allows the articleto fit variations in size as the stretchable member expands to meet thesize of the wearer. However, the seaming of the main body with thestretchable members are a major problem in the product and in themanufacturing process. The seams must be made extremely strong andcapable of handling great forces during application and use. A pantundergoes severe forces and stresses during use which may cause the sidepanels to break away or tear from the main body portion. Further,controlling these separate stretchable members severely complicates themanufacturing process and causes these pants to be more costly to theconsumer. The seams to the main body portion also tend to concentratethe fitment forces at the top and bottom of the product resulting inincreased seam tearing and poorer fit of the garment

U.S. Pat. No. 5,246,433 issued to Hasse, Bridges & Miller on Sep. 21,1993, discloses a pant having stretch laminate side panels as well aselastic waistbands and leg bands. The stretch laminates in the sidepanels provide stretch in the sides of the product to better fit thepant on the wearer. The stretch laminates are unitary with the rest ofthe pant to overcome the drawbacks associated with the pants havingseparate and discrete elastic panel members attached thereto whileimproving the fit over the conventional balloon-style pants. However,these pants suffer from the drawback that the side panels are notsufficiently stretchable to allow a wearer to easily pull the pant on bythemselves. The stretch laminates disclosed therein provide a limitedamount of stretch. Further, the materials used to form the stretchlaminates can have problems with tearing or shredding during useresulting in the products being scrapped by the manufacturer.

Another drawback with all of these products is the breathability of theproduct. The panels of the pant arc typically formed by films or foamswhich can preclude the breathability of such products. This lack ofbreathability may result in a hot stuffy product for the wearer.

It is, therefore, an object of the present invention to provide adisposable pull-on garment with a high degree of stretch such that thegarment will conformably fit wearers in a broad range of sizes.

It is a further object of the present invention to provide a disposablepull-on garment that can withstand the high wearer forces encounteredduring use while not binding the absorbent core, providing forces alongthe legs to accommodate the legs while not red marking, and providing asecure fit about the waist.

It is a still further object of the present invention to provide adisposable pull-on garment having a continuous belt which has variouszones of elastic extensibility that will not bind the absorbent corewhile providing better fit at the waist and the legs.

It is a further object of the present invention to provide a disposablepull-on garment with a high degree of breathability in at least the sidepanels and more preferably in the waistband zones, to allow vaportransmission so that the garment is not hot and stuffy.

SUMMARY OF THE INVENTION

The disposable pull-on garments of the present invention preferably areunitary disposable absorbent garments such as a pull-on diapers ortraining pants capable of is withstanding the forces encountered duringuse while being relatively simple and cost effective to manufacture. Thepull-on garment is provided with a continuous belt in the front regionand the back region to distribute the forces generated during use inorder to better fit the pull-on garment on the wearer. The continuousbelt has a central panel comprising an elastically contractiblewaistband panel and a non-binding medial panel, extensible side panelson either side of the central panel, and seam panels such that the sidesand upper central waist of the garment expand to allow the garment to bedonned easily, move with the wearer during use, maintain the fit of thegarment during use, and hold the absorbent core close to the body tobetter contain discharged exudates while not binding the absorbent corein a manner which increases the likelihood of leakage In especiallypreferred embodiments, the pull-on garment is not uncomfortable for thewear because it is provided with means which allow vapor transmissionvia vents or aperture or using breathable materials to form the garment.

In an especially preferred embodiment, the pull-on garment comprises achassis layer comprising a continuous sheet that defines a front region,a back region, and a crotch region; a first belt layer joined to thechassis layer in the front region; a second belt layer joined to thechassis layer in the back region; and elastic panel members positionedbetween the belt layers and the chassis layer which laminate ismechanically stretched to form elastically extensible stretch laminatesin both the front region and the back region in the side panels; andseams joining the front region to the back region so as to form the legopenings and waist openings. The continuous chassis layer and beltlayers in conjunction with other elements thus form the continuous beltof the pull-on garment. Because the belt layers extend continuouslylaterally across the waist region and do not cover the entire crotchregion, and because the chassis layer is thus exposed in the crotchregion, the pull-on garment has a unique aesthetic feature whichconsumers perceive as providing a cloth-like feel in the waist andbetter containment characteristics in the crotch region The pull-ongarment also preferably comprises an elastic waist feature and elasticleg features, more preferably an absorbent assembly such as a topsheetand an absorbent core to contain body exudates, and most preferablyapertures and vents in at least the side panels to enhance thebreathability of the pull-on garment.

BRIEF DESCRIPTION OF THE DRAWINGS

While the specification concludes with claims particularly pointing outand distinctly claiming the subject matter which is regarded as formingthe present invention, it is believed that the invention will be betterunderstood from the following description which is taken in conjunctionwith the accompanying drawings and which like designations are used todesignate substantially identical elements, and in which:

FIG. 1 is a perspective view of the disposable pull-on garment of thepresent 20 invention in a typical in use configuration;

FIG. 1A is a simplified plan view of the pull-on garment of the presentinvention in its flat uncontracted condition showing the various panelsor zones of the garment;

FIG. 2 is a plan view of the pull-on garment of the present invention inits flat uncontracted condition showing the outer surface and havingportions cut away to reveal underlying structure;

FIG. 3 is a fragmentary view of the pull-on garment shown in FIG. 2taken along section line 3-3 of FIG. 2;

FIG. 4 is a plan view of the pull-on garment of the present invention inits flat uncontracted condition showing the inner surface and havingportions cut away to reveal underlying structure;

FIG. 5 is a cross-sectional perspective view of an alternativeembodiment of the pull-on garment of the present invention;

FIG. 6 is a cross-sectional perspective view of a further alternativeembodiment of the pull-on garment of the present invention;

FIG. 7 is a cross-sectional perspective view of a still furtheralternative embodiment of the pull-on garment of the present invention;

FIG. 8 is a fragmentary cross-sectional view of an alternative elasticleg feature in the crotch region for use on the pull-on garment of thepresent invention;

FIG. 8A is a fragmentary cross-sectional view of the elastic leg featureshown in FIG. 8 in the front region;

FIG. 9 is a plan view of an alternative embodiment of the presentinvention wherein the chassis layer has been “windowed” to increase thebreathability of the pull-on garment in the waistband panel;

FIG. 10 is a cross-sectional perspective view of a still furtheralternative embodiment of the pull-on garment of the present invention;

FIG. 11 is a plan view of a seam pattern of the present invention;

FIG. 12 is a graph of the stress/strain curve in grams per 1 inch widesample of a particularly preferred elastomeric material for use as theelastic panel member in the stretch laminates of the present invention;

FIG. 13 is a graph of stress/strain, both extension and recovery curves,in gram per 1 inch wide sample of a stretch laminate of the presentinvention that does not have vents; and

FIG. 14 is a graph of the stress/strain curve in grams per 1 inch widesample of the stretch laminate of FIG. 13 showing the force wallgenerated by these stretch laminates.

DETAILED DESCRIPTION OF THE INVENTION

As used herein, the term “pull-on garment” refers to articles of wearwhich have a defined waist opening and a pair of leg openings and whichare pulled onto the body of the wearer by inserting the legs into theleg openings and pulling the article up over the waist. The term“disposable” is used herein to describe garments which are not intendedto be laundered or otherwise restored or reused as a garment (i.e., theyare intended to be discarded after a single use and, preferably, to berecycled, composted or otherwise disposed of in an environmentallycompatible manner). A “unitary” pull-on garment refers to pull-ongarments which are formed of separate parts united together to form acoordinated entity, but the side panels are not separate elements joinedto a separate chassis in that the side panels are formed by at least onelayer which also form: the central panel or chassis of the garment(i.e., the garment does not require separately manipulative panels suchas a separate chassis and separate side panels). The pull-on garment isalso preferably “absorbent ” to absorb and contain the various exudatesdischarged from the body. A preferred embodiment of the pull-on garmentof the present invention is the unitary disposable absorbent pull-ongarment, pull-on diaper 20, shown in FIG. 1. As used herein, the term“pull-on diaper” refers to pull-on garments generally worn by infantsand other incontinent individuals to absorb and contain urine and feces.It should be understood, however, that the present invention is alsoapplicable to other pull-on garments such as training pants, incontinentbriefs, feminine hygiene garments or panties, and the like.

FIG. 1 is a perspective view of the pull-on diaper 20 of the presentinvention The pull-on diaper 20 has an outer surface 22, an innersurface 24 opposed to the outer surface 22, a front region 26, a backregion 28, a crotch region 30, and seams 32 which join together thefront region 26 and the back region 28 to form leg openings 34 and awaist opening 36. A continuous belt 38 is formed about the waist opening36. The continuous belt 38 acts to dynamically create fitment forces andto distribute the forces dynamically generated during wear. The pull-ondiaper 20 thus preferably comprises a chassis layer 40; a first beltlayer 42; a second belt layer 44; an elastically extensible stretchlaminate positioned in each side panel of the front region 26, frontstretch laminates 46; an elastically extensible stretch laminatepositioned in each side panel of the back region 28, back stretchlaminates 48; and an elastic waist feature 50 positioned in both thefront region 26 and the back region 28. The pull-on diaper 20additionally comprises elastic leg features 52. (In an alternativeembodiment, apertures or vents (not shown) are most preferably providedin at least the side panels of the pull-on diaper 20 to providebreathability and ventilation.) Because the first belt layer 42 and thesecond belt layer 44 (the belt layers) are preferably nonwoven webshaving the appearance of cloth and the chassis layer 40 is preferably aplastic film, the pull-on diaper 20 has a unique aesthetic feature inthat it is perceived by caregivers and wearers to have a garment-likecomfort and feel in the waist regions while having a perceivedcontainment benefit in the crotch region.

FIG. 1A shows a simplified plan view of the pull-on diaper 20 of FIG. 1in its flat-out, uncontracted state depicting the various panels andtheir positioning with respect to each other. The term “panel” is usedherein to denote an area or element of the pull-on diaper or the belt.(While a panel is typically a distinct area or element, a panel maycoincide (functionally correspond) somewhat with an adjacent panel.) Thepull-on diaper 20 has a crotch region 30 comprising a main panel 56 anda pair of leg flap panels 58; a front region 26 comprising a centralpanel comprising a waistband panel 60 and a medial panel 62, side panels64, and seam panels 66; and a back region 28 comprising a central panelcomprising a waistband panel 60′ and a medial panel 62′, side panels64′, and seam panels 66′. The crotch region 30 is the portion of thepull-on diaper 20 from which the continuous belt (the other panels)emanates. The absorbent core is generally positioned within the mainpanel 56 since exudates are typically discharged in this region althoughthe absorbent core will typically extend into the medial panels 62 and62′ of the belt. A leg flap panel 58 extends generally laterallyoutwardly from and along each side edge 68 of the main panel 56. Eachleg flap panel 58 generally forms at least a portion of the elastic legfeature. The continuous belt (the front region 26 and the back region28) extends generally longitudinally outwardly from and along eachlateral edge 69 of the crotch region 30 (the main panel 56 and the legflap panel 58). In the front region 26, the medial panel 62 of thecentral panel extends generally longitudinally outwardly from and alongthe lateral edge 69 of the crotch region 30. The waistband panel 60extends generally longitudinally outwardly from and along the medialpanel 62. The side panels 64 each extend generally laterally outwardlyfrom and along the central panel. The seam panels 66 each extendgenerally laterally outwardly from and along the respective side panel64. In the back region 28, the medial panel 62′ of the central panelextends generally longitudinally outwardly from and along the otherlateral edge 69 of the crotch region 30. The waistband panel 60′ extendsgenerally longitudinally outwardly from and along the medial panel 62′.The side panels 64′ each extend generally laterally outwardly from andalong the central panel. The seam panels 66 each extend generallylaterally outwardly from and along the respective side panel 64′. Thefront region 26, in addition to its panel, also has an end edge 70, legedges 71, and side edges 72. The back region 28, in addition to itspanels, also has an end edge 70′, leg edges 71, and side edges 72′. Thecrotch region 30 has leg edges 74.

FIG. 2 is a partially cut-away plan view of the pull-on diaper 20 ofFIG. 1 in its flat-out, uncontracted state (i.e., with elastic inducedcontraction pulled out except in the side panels 64 wherein the stretchlaminates (front stretch laminates 46 and back stretch laminates 48) areleft in their relaxed condition) with the outer surface 22 facing theviewer, prior to the front region 26 and the back region 28 being joinedtogether by the seams 32. The outer surface 22 of the pull-on diaper 20comprises that portion which is positioned away from the wearers bodyduring use. In the embodiment shown, the outer surface 22 of the pull-ondiaper 20 comprises the first belt layer 42 in the front region 26, thesecond belt layer 44 in the back region 28, and the chassis layer 40 inthe crotch region 30. (The inner surface 24 of the diaper is opposed tothe outer surface 22 and comprises that portion of the diaper which ispositioned adjacent to the wearer's body during use.)

In the embodiment shown in FIG. 2, the chassis layer 40 preferablycomprises a continuous sheet or web which defines the front region 26,the back region 23, and the crotch region 30. Thus, the chassis layer 40is the primary stratum or layer of the pull-on diaper. (As used herein,the term “layer” does not necessarily limit the element to a singlestrata of material in that a layer may actually comprise laminates orcombinations of sheets or webs of the requisite type of materials.) Thechassis layer 40 has an inner surface 76 (not shown in FIG. 2) and anouter surface 77. The inner surface 76 and outer surface 77 of thechassis layer 40 correspond in their orientation with the inner surface24 and the outer surface 22 of the pull-on diaper 20. Since the chassislayer 40 preferably defines the front region 26, the back region 28, andthe crotch region 30, the chassis layer 40 also has correspondingregions and panels as previously defined. (For simplicity, these regionsand panels are denoted in the drawings by the same reference numerals asthe corresponding pull-on diaper region and panels as shown in FIG. 1A.)The first belt layer 42 is positioned on the outer surface 77 of thechassis layer 40 in the front region 26 and extends continuouslylaterally across the front region 26 from one side edge 72 to the otherside edge 72 and longitudinally from the end edge 70 to at least the legedges 71. Tee first belt layer 42 is preferably joined to the chassislayer 40. The second belt layer 44 is positioned on the outer surface 77of the chassis layer 40 in the back region 28 and extends continuouslylaterally across the back region 28 from one side edge 72′ to the otherside edge 72′ and from the end edge 70′ to at least the leg edges 71′.The second belt layer 44 is preferably joined to the chassis layer 40.Thus, each belt layer in combination with the chassis layer 40 forms acontinuous belt (as shown in FIG. 1) about the waist of the wearer. Aswill be detailed below, this belt has various elastic extensionproperties in various zones to enhance the fit and containment of thepull-on diaper 20.

Elastically extensible stretch laminates (front stretch laminates 46 andback stretch laminates 48) are formed in each side panel of both thefront region 26 and the back region 28. Each front stretch laminate 46at least comprises the portion of the first belt layer 42 in the sidepanel and an elastic panel member 78 joined thereto, and, in thisparticular embodiment, the portion of the chassis layer 40 forming theside panel. Preferably, the elastic panel member 78 is positionedbetween the chassis layer 40 and the first belt layer 42, and morepreferably extends longitudinally from the end edge 70, most preferablyto the leg edge 71. Each rear stretch laminate 48 at least comprises theportion of the second belt layer 44 in each side panel and an elasticpanel member 78′ joined thereto, and, in this particular embodiment, theportion of the chassis layer 40 forming the side panel. Preferably, theelastic panel member 78′ is positioned between the chassis layer 40 andthe second belt layer 44, and more preferably extends longitudinallyfrom the end edge 70′, most preferably to the leg edge 71′. In thepull-on diaper embodiment shown in FIG. 2, each stretch laminatepreferably further comprises a portion of the topsheet 80 (the barrierlayer) in the side panel. Each stretch laminate is mechanicallystretched or drawn (designated by the strain lines) to allow the stretchlaminate to be elastically extensible in at least the lateral direction.(The lateral direction (x direction or width) is defined as thedirection parallel to the lateral centerline of the pull-on diaper, thelongitudinal direction (y direction or length) is defined as thedirection parallel to the longitudinal centerline; and the axialdirection (z direction or thickness) is defined as the directionextending through the thickness of the pull-on diaper.)

An elastic waist feature 50 is provided in the waistband panel of thefront region 26, the back region 28, or preferably both the front region26 and the back region 28. The elastic waist feature 50 provides anelastically extensible member, preferably a gathered elasticallycontractible member, to dynamically fit and conform to the waist of thewearer in the central panels. In the embodiment shown, the elastic waistfeature 50 preferably comprises a unitary waistcap/waistband 82operatively joined in the waistband panel in an elastically contractiblecondition, preferably to the primary layer of the topsheet 80. Theunitary waistcap/waistband 82 acts as a barrier to the leakage ofexudates out of the waist opening of the pull-on diaper 20 as well as acontractible waistband to provide fit of the pull-on diaper 20 about thewaist of the wearer. In the most preferred embodiments, the unitarywaistcap/waistband is also breathable to allow venting of water vaporout of the pull-on diaper adjacent the waist opening.

The pull-on diaper 20 is also provided with elastic leg features 52 toimprove fit at the legs in the crotch region 30. The pull-on diaper 20additionally comprises a topsheet 80 and an absorbent core 84 positionedbetween the topsheet 80 and the chassis layer 40 to provide an absorbentassembly that cooperates with the continuous belt to contain dischargedexudates. Apertures or vents (not shown) may also be positioned in theside panels to provide breathability or ventilation.

FIG. 3 is a cross-sectional perspective view of the pull-on diaper 20 ofthe present invention taken along line 3-3 of FIG. 2 in the front region26. The chassis layer 40 is shown to form the primary strata or layer ofthe pull-on diaper 20 and has an inner surface 76 and an outer surface77. The first belt layer 42 is positioned on the outer surface 77 of thechassis layer 40 to form the outer surface 22 of the pull-on diaper 20in the front region 26. The elastic panel members 78 are preferablypositioned between the first belt layer 42 and the chassis layer 40. Thetopsheet 80 is positioned on and joined to the inner surface 76 of thechassis layer 40. The topsheet 80 preferably comprises a liquid perviousprimary layer 86 and two barrier layers 83. The barrier layers 88 extendlaterally outwardly from the primary layer 86 to the side edges 72. Eachbarrier layer 88 comprises a flap portion 90 and a stand-up portion 92.The stand-up portion 92 is not attached to the primary layer 86 to allowthe gathering forces of the elastic spacing member(s) 94 to cause thestand-up portion 92 to stand up away from the surface of the primarylayer 86 to form a barrier or wall in use. The flap portion 90 extendslaterally outwardly from the stand-up portion 92 (the proximal edge) tothe side edge 72. The absorbent core 84 is preferably positioned betweenthe primary layer 86 and the chassis layer 40. The construction of theback region 28 is preferably identical to the construction of the frontregion 26.

FIG. 4 is a partially cut-away plan view of the pull-on diaper 20 of thepresent invention in its flat-out, uncontracted state (i.e., withelastic induced contraction pulled out except in the side panels whereinthe stretch laminates are left in their relaxed condition) with theinner surface 24 of the pull-on diaper 20 facing the viewer, prior tothe front region 26 and the back region 28 being joined together by theseams. In order to provide the necessary absorbency to contain bodyexudates, the pull-on diaper 20 comprises a liquid pervious topsheet 80and an absorbent core 84 positioned between the topsheet 80 and thechassis layer 40 In the embodiment shown in FIG. 4) the topsheet 80preferably comprises three distinct layers joined together. A liquidpervious primary layer 86 is positioned over the absorbent core 84 torapidly absorb liquids into the product. Barrier layers 88 are joined tothe primary layer 86 and are preferably drawable, more preferablyhydrophobic, to allow the side panels to be mechanically stretchedwithout ripping or tearing while providing barrier cuffs along the sidesof the pull-on diaper 20. The barrier layers 88 have a flap portion 90and a channel or stand-up portion 92 to provide the various componentsof the elastic leg features 52. The elastic leg features 52 preferablycomprise a gasketing cuff and a barrier cuff. The gasketing cuff ispreferably formed by one or more elastic leg members 96 operativelyjoined to the chassis layer 40, the barrier layer 88, or both,preferably between the chassis layer 40 and the flap portion 90 of thebarrier layer 88 in the leg flap panel of the crotch region 30. Thebarrier cuff is preferably formed by a flap (the stand-up portion 92 ofthe barrier layer 88), closing means 98 for securing the longitudinalends of the stand-up portion 92 to the primary layer 86, and an elasticspacing member 94 operatively joined to the stand-up portion 92.

In the construction of the pull-on diaper of the present invention as isshown in FIG. 1, a continuous belt 38 is formed about the waist opening36. This belt 38 acts to dynamically create fitment forces in thepull-on diaper when positioned on the wearer, to maintain the pull-ondiaper on the wearer even when loaded with body exudates thus keepingthe absorbent core in close proximity to the wearer, and to distributethe forces dynamically generated during wear about the waist therebyproviding supplemental support for the absorbent core without binding orbunching the absorbent core in the medial panel of the pull-on diaper.The belt is designed to be elastically extensible in certain segmentsand at least elastically extensible, preferably elasticallycontractible, in other segments about the waist opening; to beelastically extensible about a portion of the leg opening; and to not begathered or bunched in the medial panel where the absorbent core islocated. The elastic extensibility of the belt also has a“force/extension wall” beyond which the belt will not elastically extendin order to allow the pull-on diaper to be more easily applied since thediaper will not stretch excessively thereby allowing the product toslide more easily over the buttocks. This “force/extension wall” isespecially important for small children who self apply the product andwould be unable to completely pull and position a fully stretchableproduct over their buttocks. The belt also manages wearing stressesbetter with the belt webs encircling the absorbent core. The resultantdiaper is less bulky in its fit about the waist of the wearer. The lackof gathering or contraction in the belt over the absorbent core inconjunction with the continuity of the belt across the absorbent corealso provides improved fit by providing a continuous normal force basedon the hoop stresses generated in the belt which tends to press theabsorbent core against the body during wear. Thus, the absorbent core ismaintained in a closer, more comfortable, and less gapping way thanthose diapers which provide elastic contraction or gathering over thearea of the absorbent core or those that do not provide a belt toconcentrate within the span and distribute across the span the hoopstresses about the area of the absorbent core.

As shown in FIG. 1A, the belt 38, in both the front region 26 and theback region 28 respectively, comprises a central panel comprising awaistband panel 60 and 60′ and a medial panel 62 and 62′, a side panel64 and 64′ on each side of the central panel, and a seam panel 66 and66′ at each side panel 64 and 64′. The side panels are elasticallyextensible to provide fit within the sides of the pull-on diaper. Thewaistband panel is elastically extensible, preferably elasticallycontractible or gathered, to better fit the pull-on diaper in thecentral part of the waist opening. The medial panel is not gathered inorder to maintain the integrity of the absorbent core during use.Although the medial panel may be elastically extensible (but notgathered) as discussed herein, in the embodiments shown in FIGS. 14, themedial panel is preferably not extensible. The continuous belt 38 may beformed from a number of different materials and layers as defined below.The belt 38 comprises at least a first belt layer 42 and a second beltlayer 44 joined together on each side at the seam panels 66 and 66′. Inthe embodiment shown in FIGS. 14, the belt 38 preferably comprises aportion of the chassis layer 40, the belt layers (the first belt layer42 in the front region 26 and the second belt layer 44 in the backregion 28), stretch laminates (front stretch laminates 46 and backstretch laminates 48) in the side panels, and an elastic waist feature50 in each waistband panel, preferably comprising a unitarywaistcap/waistband 82 operatively joined in an elastically contractiblecondition to gather the belt 38 in the waistband panels 60 and 60′.

In preferred embodiments of the present invention, the chassis layer 40generally determines the overall shape of the pull-on diaper 20. Thechassis layer 40 acts as the main structural layer of the pull-on diaperto which other features may be added or joined. The chassis layer isthus positioned in all or most of the surface area of the pull-ondiaper, although in certain embodiments certain portions of the chassislayer may be apertured, cut-out or removed (“windowed”) to enhancestretchability and/or breathability of the pull-on diaper or features ofthe pull-on diaper in that area The chassis layer thus preferablycomprises a continuous sheet or web which does not have “joints” orseams such that forces are distributively transmitted through the entirelayer. As previously discussed herein, the continuous sheet or web ofthe chassis layer can comprise a single web of material or a laminate ofseveral continuous webs or layers of different materials. The chassislayer forms a part of the continuous “belt” that provides the necessaryforce/extension properties to hold the diaper on the wearer whileexpanding to allow the pull-on diaper to be put on easily. The chassislayer may form the outer surface, the inner surface, or portions ofeither or both, or may be entirely positioned in the interior of thepull-on diaper. In the embodiment of the present invention shown inFIGS. 1-4, the chassis layer preferably forms the outer surface of thepull-on diaper in the crotch region to provide the unique aesthetics ofthe pull-on diaper.

Since at least a portion of the chassis layer 40 is subjected tomechanical stretching in order to provide the stretch laminates in theside panels, it is preferably elongatable, more preferably drawable (butnot necessarily elastomeric), so that the chassis layer will, uponmechanical stretching, be at least to a degree permanent elongated suchthat it will not fully return to its original undistorted configuration.The chassis layer may thus comprise any of the materials known for usein absorbent article such as woven or nonwoven webs; polymeric filmssuch as thermoplastic films of polyethylene, polypropylene, or blendsthereof; laminates of such materials; or composite materials. Inpreferred embodiments, the chassis layer can be subjected to mechanicalstretching with minimal or no rupturing or tearing. Therefore, thechassis layer 40 is preferably a polymeric film.

Because the chassis layer 40 is preferably a polymeric film, it is alsogenerally impervious to liquids (e.g., urine) so that it may also serveas the component which prevents exudates absorbed and contained in theabsorbent core from wetting garments which contact the pull-on diapersuch as bed sheets and undergarments (i.e., it acts as the traditionaldiaper backsheet). If the chassis layer is not liquid impervious,typically an additional layer such as a traditional backsheet should beused behind the absorbent core. The chassis layer may also be breathable(pervious to air or water vapor) if desired. In particular, since thebelt layers, and preferably the barrier layers, are each drawablenonwoven webs to strengthen the stretch laminates to carry the forcesand since there is no need for a high lateral tensile strength materialin the crotch region, the chassis layer can alternatively comprisebreathable materials that are microporous and that are, typically, lowerin strength and elongation. An example of such a film is thatmanufactured by Exxon Chemical Company under the tradename EXXAIRE.Exemplary films for use as the chassis layer of the present inventionhaving relatively good drawability but that are not breathable includepolymeric films manufactured by Clopay Corporation of Cincinnati, Ohiounder the designation Clopay 1401, or films available from Tredegar ofTerre Haute, Ind., under the designation X-8323 or X-9954.

The size of the chassis layer is dictated by the size of the wearer thepull-on diaper is designed to fit In a preferred embodiment, the chassislayer has a modified hourglass shape to better fit the wearer. In apreferred embodiment designed to fit large toddlers (about 9 kg to about15.4 kg), the chassis layer 40 is preferably about 483 mm (about 19inches) long by about 234 mm (about 9 ¼ inches) wide in the front regionand the back region and about 165 mm (about 6 ½ inches) wide in thecrotch region. The central panel is 135 mm (about 5 ¼ inches) wide, theside panels we is about 41 mm (about 1 ⅝ inches) wide, the activatedportion of the side panels is about 32 mm (about 1 ¼ inches) wide, andthe seam panels are about 8.5 mm (about {fraction (5/16)} inch) wide.(The actual area of overlap of the seam panels is about 11 mm in thepreferred embodiments shown herein.) The front region is about 114 mm(about 4 ½ inches) long, the back region is about 165 mm (about 6 ½inches) long and the crotch region is about 220 mm (about 8 ⅝ inches)long.

The belt layers (first belt layer 42 and second belt layer 44) act,preferably in conjunction with the chassis layer 40 and othercomponents, to form the continuous belt 38 about the waist opening 36 ofthe pull-on diaper 20. The belt layers each thus prefer comprise acontinuous sheet or web that does not have “joints” or seams such thatforces are distributively transmitted through the entire belt layer.(The continuous sheet or web of each belt layer can comprise a singleweb of material or a laminate of several continuous webs or layers ofdifferent materials.) The materials of the belt layers also preferablyprovide strength to the stretch laminates in the side panels to laminatethe materials together and permit mechanical stretching without undueripping, tearing or shredding of the materials.

In the embodiment shown in FIGS. 1-4, the belt layers are preferablypositioned on and joined to the outer surface of the chassis layer so asto form a portion of the outer surface of the pull-on diaper. However,the belt layers may be positioned on the inner surface of the chassislayer, and, in some embodiments, may form a portion of the inner surfaceof the pull-on diaper. Some of these alternative embodiments are shownand described hereinafter. The belt layers are joined to the chassislayer by attachment means (not shown) at least in the side panel.Suitable attachment means are described herein. The belt layers extendlaterally continuously across the respective waist region (front regionor back region) of the pull-on diaper to provide the continuous belt 38described herein and extend longitudinally from the end edge to aboutthe crotch region. Alternatively) the belt layers may longitudinallyextend into the crotch region to provide more of the pull-on diaper witha garment-like feel. While it is preferred that the first belt layer andthe second belt layer extend longitudinally inward so as to leave a gapbetween them in the crotch region to provide the aesthetic benefitdescribed herein, they can be overlapped, if desired, to provide anoverall cloth-like appearance and feel.

Since the belt layers are subjected to mechanical stretching in the sidepanels, the belt layers are preferably elongatable, more preferablydrawable (but not necessarily is elastomeric), without undue or,preferably any, tearing or ripping. Further, because the belt layers arepreferably positioned on the outer surface of the pull-on diaper, thebelt layers are preferably also compliant, soft feeling andnon-irritating to the wearer's skin to give the diaper the feel andcomfort of a cloth garment. Suitable belt layers can be manufacturedfrom a wide range of materials such as plastic films; apertured plasticfilms; woven or nonwoven webs of natural fibers (e.g., wood or cottonfibers), synthetic fibers (e.g., polyolefins, polyamides, polyester,polyethylene, or polypropylene fibers), or a combination of naturaland/or synthetic fibers; or coated woven or nonwoven webs. Preferably,the belt layers comprise a nonwoven web of synthetic fibers.

In typical nonwoven webs, localized rupturing of the web is caused incertain regions as the web is passed between the mechanical stretchingrolls. This rupturing may be attributed to a lack of necessaryextensibility of the nonwoven web or to a lack of drawability of theindividual fibers. The preferred nonwoven webs of the present inventionexhibit high extensibility and preferably allow the individual fibers tobe drawn such that the bonds between the fibers are not substantiallyruptured or broken. Thus, the belt layers are most preferably highlyextensible nonwoven webs that will generally more uniformly elongatewith minimal localized strain tearing occurring compared to typicalnonwoven webs consisting of less drawable fibers. Examples of suchnonwoven webs include spunbonded webs of polyethylene orpolyethylene-blend fibers. More preferably, the belt layers are madefrom a spunbonded web of fibers made of polyethylene, polyethylenepolymer blends, or polyethylene/polypropylene polymer blends. Exemplaryspunbonded nonwoven webs of polyethylene fibers for use as the beltlayers are available as #87257 manufactured by Polybond Co. ofWaynesboro, Va.; as COROLIND 17184 manufactured by Corovin of Peine,Germany; or as Fiberweb E1004204 manufactured by Fiberweb ofSimpsonville, S.C.

The belt 38 is elastically extensible in the side panels 64 and 64′ toprovide a more comfortable and contouring fit by initially conformablyfitting the pull-on diaper to the wearer and sustaining this fitthroughout the time of wear well past when it has been loaded withexudates by distributing forces along both the waist and legs since thesides of the pull-on diaper can expand and contract. The side panels areextensible in at least one direction, preferably in a direction having avector component in the lateral direction, more preferably in thelateral direction, to provide better fit. It should be noted, however,that the side panels may be extensible in any other direction or in morethan one direction. In addition, the side panels may have one or morediscrete zones of extensibility.

The elastic extensibility in the side panels may be provided by a numberof different materials and configurations. Various components of thebelt (e.g., the belt layers or the chassis layer) may compriseconventional elastic materials or the side panels of the belt may beconstructed from a number of different elastic laminate structures. Forexample, the side panels of the belt can comprise an elastic materialoperatively joined to one or more inelastic components (belt layer orchassis layer or both) in an elastically contractible condition such asis described in U.S. Pat. No. 3,860,003 entitled “Contractable SidePortions For A Disposable Diaper” issued to Buell on Jan. 14, 1975,which is incorporated herein by reference. Alternatively, the sidepanels can comprise a structural elastic-like film (SELF) web such asdescribed in WO 95/03765, “Web Materials Exhibiting Elastic-likeBehavior”, The Procter & Gamble Company, published Feb. 9, 1995, whichis incorporated herein by reference. While the side panels of the beltmay be constructed from a number of different extensible or elasticmaterials as are known in the art, one or more, and preferably each, ofthe side panels of the belt are constructed of a stretch laminate.

The stretch laminates (front stretch laminates 46 and back stretchlaminates 48) are unitary elements of the pull-on diaper (i.e., they arenot separately manipulative elements secured to the pull-on diaper, butrather are formed from and are extensions of one or more of the variouslayers (at least the belt layer, preferably also the chassis layer) ofthe pull-on diaper.) In a preferred embodiment, each stretch laminate isformed by a portion of the chassis layer, a portion of the respectivebelt layer, an elastic panel member positioned between the chassis layerand the belt layer, and a portion of the barrier layer.

In a preferred embodiment of the present invention, an elastic panelmember 73 is operatively joined in the side panel, preferably betweenthe chassis layer and the belt layers, to allow the stretch laminates tobe elastically extensible in at least the lateral direction. As usedherein, the term “elastically extensible” means a segment or portionthat will elongate in at least one direction (preferably the lateraldirection for the side panel) when tensional forces (typically lateraltensional forces for the side panel) are applied, and will return toabout its previous size and configuration when the tensional forces areremoved. Elastomeric materials which have been found to be especiallysuitable for use as the elastic panel members (especially for zerostrain stretch laminates) are styrenic block copolymer based elasticfilms, preferably with a thickness of 0.05 mm-0.064 mm (0.002 in-0.0025in), such as arc made by Clopay Corporation of Cincinnati, Ohio underthe designation PA18-2870; or Exxon 500 series elastic films from ExxonChemical of Baytown, Tex. A stress/strain (force/extension) graph of theP18-2870 elastomeric material described above is shown in FIG. 12. Thestress/strain graph shows the typical shape of the force curve in gramsper 1 inch wide sample when subjected to an applied strain or extensionat a rate of 50.8 cm/min (20 in/min) at about 23° C. (room temperature).Other suitable elastomeric materials for use as the elastic panelmembers include “live” synthetic or natural rubber, other synthetic ornatural rubber foams, elastomeric films (including heat shrinkableelastomeric films), elastomeric woven or nonwoven webs, scrims,elastomeric composites, or the like.

In an especially preferred embodiment, the elastic panel members areoperatively joined in the side panel by securing them to the chassislayer, the belt layer, or both while in a substantially untensioned(zero strain) condition. At least a portion of the resultant compositestretch laminate containing the elastic panel member is then subjectedto mechanical stretching sufficient to permanently elongate thenon-elastic components (the chassis layer, the barrier layer, and thebelt layer) of the stretch laminate. The composite stretch laminate isthen allowed to return to its substantially untensioned condition. Theside panel is thus formed into a “zero strain” stretch laminate.(Alternatively, the elastic panel member could be operatively joined ina tensioned condition and then subjected to mechanical stretching;although this is not as preferred as a “zero strain” stretch laminate.)As used herein, the term “zero strain” stretch laminate refers to alaminate comprised of at least two plies of material which are securedto one another along at least a portion of their coextensive surfaceswhile in a substantially untensioned (“zero strain”) condition; one ofthe plies comprising a material which is stretchable and elastomeric(i.e., will return substantially to its untensioned dimensions after anapplied tensile force has been released) and a second ply which iselongatable (but not necessarily elastomeric) so that upon stretchingthe second ply will be, at least to a degree, permanently elongated sothat upon release of the applied tensile forces, it will not fullyreturn to its original undeformed configuration. The resulting stretchlaminate is thereby rendered elastically extensible, at least up to thepoint of initial stretching, in the direction of initial stretching.Particularly preferred methods and apparatus used for making stretchlaminates utilize meshing corrugated rolls to mechanically stretch thecomponents. Particularly preferred apparatus and methods are disclosedin U.S. Pat. No. 5,167,897 issued to Weber et al. on Dec. 1, 1992; U.S.Pat. No. 5,156,793 issued to Buell et al. on Oct. 20, 1990; and U.S.Pat. No. 5,143,679 issued to Weber et al. on Sep. 1, 1992; each of whichare incorporated herein by reference.

The elastic panel members can be operatively joined in the stretchlaminate to the chassis layer, the belt layers, or both, using either anintermittent bonding configuration or a substantially continuous bondingconfiguration. As used herein, an “intermitently” bonded laminate webmeans a laminate web wherein the plies are initially bonded to oneanother at discrete spaced apart points or a laminate web wherein theplies are substantially unbonded to one another at discrete spaced apartareas. Conversely, a “substantially continuously” bonded laminate webmeans a laminate web wherein the plies are initially bondedsubstantially continuously to one another throughout the areas ofinterface. Because it is preferred that the stretch laminate be bondedover all or a significant portion of the stretch laminate so that theinelastic webs (belt layers, chassis layer, and barrier layers) elongateor draw without causing rupture, and the layers of the stretch laminatesare preferably bonded in a configuration that maintains all of thelayers of the stretch laminate in relatively close adherence to oneanother after the incremental mechanical stretching operation, theelastic panel members and the other plies of the stretch laminate aresubstantially continuously bonded together using an adhesive. In aparticularly preferred embodiment, the adhesive selected is applied in aspiral pattern (such as is shown in U.S. Pat. No. 3,911,173 (Sprague,Jr.) and U.S. Pat. No. 4,842,666 (Werenicz)) at a basis weight of about0.00116 grams/square cm (0.0075 grams/square inch). The spirals have awidth of about 1.9 cm (0.75 in) and either are positioned just next toeach other or overlap slightly (less than 2 mm). The adhesive ispreferably an adhesive such as is available from Findley Adhesives underthe designation H2120. Alternatively, the elastic panel member and anyother components of the stretch laminates may be intermittently orcontinuously bonded to one another using heat bonding, pressure bonding,ultrasonic bonding, dynamic mechanical bonding, or any other method asis known in the art.

It has been found that the extension characteristics including theextension forces, extension modulus, and available stretch (extension);and the contractive forces and rate of contraction of the stretchlaminates are important considerations in the performance of both thestretch laminates and the pull-on diaper. The extension properties andfitment forces give the applicator and the wearer the overall perceived“stretchiness” during use. They also effect the ability of theapplicator to achieve a suitable degree of application stretch (i.e.,for a “normally” perceived tensioning of the diaper during application,the total amount of resultant stretch is that desired toachieve/maintain good conformity of fit). A stretch laminate with arelatively high extension modulus/force can cause red marking on thewearer's skin while a relatively low extension modulus/force can causesagging/slipping on the wearer. Stretch laminates having too littleavailable stretch may not achieve a suitable level of body conformityand may contribute in making the diaper uncomfortable to wear and hardto put on. Stretch laminates with very low contractive forces (orexcessive elastic creep, excessive elastic force relaxation, orexcessive inelastic “set”) may not stay in place on the wearer and maytend to sag/slip on the wearer resulting in poor fit and containment.

For the stretch laminates of the present invention it has been foundthat the extension characteristics of extension force and extensionmodulus are preferably within defined ranges. FIG. 13 shows anextension/force response curve for two extension/recovery cycles on apreferred (nonvented) stretch laminate of the present invention. Thesample stretch laminate is subjected to an initial pull or extension ata rate of 50.8 cm/min (20 in/min) at about 23° C. and held for 30seconds at 200% extension. The sample is then allowed to relax at thesame rate. The sample is allowed to remain unconstrained for one minutebefore being subjected to a second pull or extension at the same rateand conditions. The initial pull extension force preferably is greaterthan or equal to about 100 grams per 1 inch wide sample at 100%extension. More preferably, the initial pull extension forces arebetween about 150 to about 225 grams per 1 inch wide sample, mostpreferably between about 160 grams per 1 inch wide sample and 200 gramsper 1 inch wide sample, at 100% extension to best fit the wearer. At200% extension, the initial pull extension forces are preferably betweenabout 200 grams per 1 inch per wide sample and about 400 grams per 1inch wide sample, more preferably between about 240 grams per 1 inchwide sample and about 320 grams per 1 inch wide sample. The second cyclerecovery forces of the stretch laminates within the wearing ranges (20%to 140% extension) are preferable between about 25 grams per 1 inch widesample and about 200 grams per 1 inch wide sample on recovery, morepreferably between about 60 grams per 1 inch wide sample and about 150grams per 1 inch wide sample. These values corresponding to the nominalwearing force after extension and recovery.

The force wall is that portion of the extension curve where the forcesare more rapidly developing with increasing extension. The force wallallows additional pull-on force to be developed without additionalexcessive stretching of the belt. This results in the garment beingeasier to put on, especially for self-application. The force wall isachieved at forces greater that 400 grams per 1 inch wide sample. Thusfor the stretch laminates, an incremental increase in extension of 50%of less beyond the desired maximum design extension produces a forceabove 400 grams per 1 inch wide sample. As shown in FIG. 14, the forcewall of the stretch laminate is typically achieved at greater than about200% extension (the desired maximum design extension of this stretchlaminate). An increase in extension of 50% from 200% to 250% extensionproduces a force great than 400 grams per 1 inch wide sample.

Available stretch measures the maximum amount of material available inthe stretch laminate to reversibly stretch to conform to the wearer'sbody during wear. Thus, the amount of available stretch relates to themaximum amount of extension that the diaperer has available to fit thediaper to the wearer. In addition, the maximum amount of recoverableextension available for the diaper to comply with the wear's body. Theavailable stretch is calculated from the equation: ((stretchedlength—original length)/original length) X 100. The minimum amount ofavailable stretch required for a diaper application using the stretchlaminates is preferably an available stretch of at least about 75%,preferably at least 100%, with available stretches preferably in therange of 100%-250%, most preferably about 200%.

The continuous belt 38 is also preferably elastically extensible in thecentral panel, preferably at least in each waistband panel 60 and 60′longitudinally outward from the absorbent core. The elasticextensibility is provided by an elastic waist feature 50. The elasticwaist feature 50 provides a member that is elastically extensible,preferably elastically contractible, in at least the lateral directionso as to provide a protion of the continuous belt comprising the stretchlaminates of the side panels and the elastic waist features in thewaistband panels to dynamically fit and conform to the waist of thewearer so as to provide improved fit. Thus, lines of force along thewaist opening are resolved through the upper portions of the stretchlaminates in the side panels through the elastic waist feature in thewaistband panels. Thus, the elastic waist feature is generally thatportion of the belt extending from the end edge to the edge of theabsorbent core. The elastic waist feature is preferably elasticallycontractible in order to gather the waistband panel longitudinallyoutward from the absorbent core to taper the fit of the garment in thecentral panel to better fit the wearer.

The elastic waist feature 50 comprises an extension of at least the beltlayers (first belt layer 42 or second belt layer 44) and, preferably,one of the other elements of the pull-on diaper such as the chassislayer 40 or the topsheet 80 or any combination of these elements, alone(if one of these layers are extensible or contractible) or with anelastic material joined thereto. The elastic waist feature 50 may beconstructed in a number of different configurations including thosedescribed herein with regard to the stretch laminates; those elasticizedwaistbands such as are known in the art and as are described, forexample, in U.S. Pat. No. 4,515,595 entitled “Disposable Diapers WithElastically Contractible Waistbands” issued to Kievit & Osterhage on May7, 1935, and in U.S. Pat. No. 5,151,092, entitled “Absorbent ArticleWith Dynamic Elastic Waist Fee Having A Predisposed Resilient FlexuralHinge” issued to Buell Clear & Falcone on Sep. 29, 1992; and elasticizedwaistbands made from a structural elastic-like film (SEW) web asdescribed in the previously referenced WO 95/03765; each of which isincorporated herein by reference.

In a preferred embodiment of the present invention as shown in FIG. 4,the elastic waist feature 50 comprises a unitary waistcap/waistband 82positioned on the topsheet 80 and operatively joined in an elasticallycontractible condition with the topsheet 80 to gather the waistbandpanel 60 or 60 of the pull-on diaper 20. The unitary waistcap/waistband82 preferably comprises a laminate of a nonwoven coverstock layer, anelastomeric layer, and more preferably a second nonwoven coverstocklayer. An example of such a unitary waistcap/waistband for use herein isdisclosed in U.S. Pat. No. 5,026,364, entitled “Absorbent Article HavingUnitary Waistcap and Waistband”, issued to Robertson on Jun. 25, 1991;and which is incorporated herein by reference. The elastomeric layer ispreferably an elastomeric film such as that marketed by Exxon Chemicalunder the name Exxon 500 which is stretched to between about 50% and100% prestrain. When operatively joined to the topsheet in the centralpanel of the pull-on diaper, the unitary waistcap/waistband inconjunction with the underlying layers of the pull-on diaper provideextension forces, when stretched to 67% (1 inch in this particularembodiment) extension, preferably between about 100 grams/in and 300grams/in, more preferably between about 150 grams/in and about 200grams/in. The unitary waistcap/waistband, in this preferred embodiment,also provides at least 37 mm (1 ½ inches) of contraction (i.e. 76 mm (3inches) of contraction in the entire product) to provide a tapered fitat the upper part of the pull-on diaper.

In a particular preferred embodiment, the unitary waistcap/waistband isbreathable to allow water vapor to escape from the front region and theback region of the pull-on diaper. Breathability may be provided in theunitary waistcap/waistband by selecting relative breathable materialsfor its construction and/or by aperturing or venting thewaistcap/waistband such as is discussed herein with respect to thestretch laminates in the side panels.

The medial panels 62 and 62′ of the belt 38 are not gathered in order tonot bunch or bind the absorbent core 84 during use. In the embodimentsshown in FIGS. 1-4, the medial panels 62 and 62′ are also preferably notextensible to maintain the integrity of the absorbent core 84.Alternatively, the medial panels can be rendered elastically extensible,but not gathered, by using extensible but uncontracted materials to formthe medial panel. For example, the medial panel could comprise a zerostrain stretch laminate as used herein for the side panels or it couldcomprise the structural elastic-like film (SELF) webs as described inthe previously referenced WO 95/03765, which is incorporated herein byreference. If the medial panel is made extensible, it is preferred toallow the absorbent core to “float” (not secure the absorbent core tothe medial panel) to maintain the integrity of the absorbent core and tonot restrict the extension of the medial panel.

The seam panels 66 and 66′ are those portions of the belt 38 designed tobe seamed or bonded together by the manufacturer to form the definedwaist opening 36 and leg opening 34. As shown in FIG. 1A, the seampanels 66 and 66′ extend laterally outwardly from the respective sidepanels 66 and 64′ to the side edge 72 or 72′ and generallylongitudinally extend from the end edge 70 and 70′ to the leg edge 72 or71′, respectively. The seam panels are preferably an extension of thechassis layer and other elements such as the belt layers and thetopsheep, or any other combination of these elements. In a preferredembodiment, each seam panel is formed by portions of the chassis layer,the belt layer, the elastic panel members, and the barrier layers of thetopsheet. (In the seam panel, the stretch laminate is preferably notactivated by mechanical stretching, although it may be, if desired, toprovide additional extensibility in this region.)

Referring to FIG. 1, the seams 32 are preferably formed by bondingtogether the seam panels 66 of the front region 26 with the seam panes66′ of the back region 28. The seams 32 can be formed in a number ofdifferent ways. For example, the seams can be formed by bonding togetherportions of outwardly extending seam panels to form an outwardlyextending fin seam, bonding together portions of inwardly extending seampanels to form an inwardly extending fin seam, the seam panels may beoverlapped and bonded together to form lap seams, or the seam panels maybe bonded together using any other seam configurations that are known inthe art, such as a flangeless side seam. An example of a flangeless seamis disclosed in U.S. Pat. No. 5,236,430 entitled “Disposable TrainingPant Having Fusion-Slit Side Seams” issued to Russell P. Bridges on Aug.17, 1993, which patent is incorporated herein by reference. The bondingof the seams of the present invention can be by any suitable means wellknown in the art appropriate for the specific materials employed in theseam panels. Thus, sonic sealing, heat sealing, pressure bonding,adhesive bonding, sewing, autogeneous bonding, and the like may beappropriate techniques.

In a preferred embodiment of the present invention, the pull-on diaper20 is formed by overlapping the seam panels 66 of the front region 26with the seam panels 66′ of the back region 28 to form a lap seam. Theseam panels are preferably joined by a pattern of heat/pressure orultrasonic welds such as is shown in FIG. 11. In this particular seam,the bonding pattern comprises two rows of elliptical bonds. The totalbond seam width, W, is about 6 mm (about 0.240 in) based upon a totaloverlap, X of the seam panels of about 11 mm (about 0.4375 in). Eachbond is about 2.5 mm (about 1 in) wide, w, and about 1 mm (about 0.04in) high, h. The bonds are spaced from each other in each row, s, byabout 2 mm (about 0.08 in) center to center. Alternative patterns,dimensions, and spacing are also contemplated. With the fusion of thefirst belt layer 42, a portion of the chassis layer 40, a portion of theelastic panel member 78 in the side panels in the front region, aportion of the barrier layer 88, the second belt layer 44, a secondportion of the chassis layer 40, a portion of the elastic panel member78 in the side panels in the back region, and a second portion of thebarrier layer 88, the seam 32 is very strong and will not rip or tearduring application or wearing of the pull-on diaper 20.

A potentially strong seam may be produced by increasing certain amountsof polymeric material in the seam panels. The amount of polymericmaterial in the seam panels can be increased by using higher basisweight nonwoven materials thicker plastic films, or by introducingadditional layers of materials to the seam panels. For example,additional plastic films or nonwoven webs may be joined in the sewnpanels. Alternatively, the layers forming the diaper may be extendedbeyond the intended area of seaming and folded back into the seam panelto introduce additional strata in the seam panels. Examples of thesetypes of seams are discussed in the above-referenced U.S. Pat. No.5,236,430.

Besides the continuous belt 38, the pull-on diaper 20 comprises achassis assembly (main panel 56 and leg flap panels 58) extendingbetween the legs of the wearer to thereby define the crotch region 30.The crotch region 30 typically comprises at least an outer coveringlayer, preferably also an absorbent core 84. In the embodiment shown inFIGS. 1-4, the outer covering layer comprises the chassis layer 40 andthe topsheet 80. The chassis assembly further preferably comprises theelastic leg features 52.

The elastic leg features 52 provide improved containment of liquids andother body exudates in the crotch region 30 and about the leg openingsin general. Each elastic leg feature 52 may comprise several differentembodiments for reducing the leakage of body exudates in the leg flappanels 58 (the elastic leg feature can be and is sometimes also referredto as leg bands, side flaps, barrier cuffs, or elastic cuffs.) U.S. Pat.No. 3,860.003 entitled “Contractable Side Portions For A DisposableDiaper” issued to Buell on Jan. 14, 1975 describes a disposable diaperwhich provides a contractible leg opening having a side flap and one ormore elastic panel members to provide an elasticized leg cuff (gasketingcuff). U.S. Pat. No. 4,909,803 entitled “Disposable Absorbent ArticleHaving Elasticized Flaps” issued to Aziz and Blaney on Mar. 20, 1990,describes a disposable diaper having “stand-up” elasticized flaps(barrier cuffs) to improve the containment of the leg regions. U.S. Pat.No. 4,695,273 entitled “Absorbent Article Having Dual Cuffs” issued toLawson on Sep. 22, 1937, describes a disposable diaper having dual cuffsincluding a gasketing cuff and a barrier cuff. U.S. Pat. No. 4,795,454,entitled “Absorbent Article Having Leakage-Resistant Dual Cuffs” issuedto Dragoo on Jan. 3, 1989 discloses a disposable diaper having leakageresistant dual cuffs wherein the topsheet stops short of the side edgeof the diaper to prevent wicking out to the side of the garment. Each ofthese patents are incorporated herein by reference. While each elasticleg feature may be configured so as to be similar to any of the legbands, side flaps, barrier cuffs or elastic cuds described above, it ispreferred that each elastic leg feature comprise a combination of agasketing cuff and a barrier cuff. The gasketing cuff and barrier cuffsare preferably formed as shown in the Dragoo patent and as dice herein.

In an alternative embodiment of the present invention, the leg flappanels 58 can further comprise a structural elastic-like film (SELF) webas described in the above referenced WO 95103765. The SELF web of theleg flap panels provides extensibility in the lateral direction. Byproviding a SELF web next to, over, or outside of the elastic legmembers forming the gasketing cuff, the pull-on diaper is provided withan area adjacent the legs which can expand when needed for additionalvoid volume due to heavy loading, and also to provide a snug fit toreduce the possibility of leakage in the leg regions due to gapping. Asthe diaper is loaded and gets heavier, the weight forces cause theextensible leg flap panels to expand in the lateral direction therebyreducing gapping at the legs due to this expansion instead of the cuffbeing pulled downward by the weight and gapping away from the leg. Theresult is that action of the gasketing cuff is independent from theabsorbent core thus providing better fit and containment. Additionally,the SELF web enhances the softness of the product in the gasketing cuffand contributes to overall baby friendly aesthetics. In fact, the mainpanel, may if desired, comprise a SELF web to provide softness andcontent characteristics. Alternatively, the leg flap panels may comprisea SELF web or a mechanically stretched laminate that is extensible inthe longitudinal direction to permit extension of the leg openings inthe longitudinal direction thereby fitting wearers having larger legs.

The absorbent core 84 is preferably positioned adjacent the innersurface 76 of the chassis layer 40 and is preferably joined thereto byattachment means (not shown) such as those well known in the art. Forexample, the chassis layer may be secured to the absorbent core by auniform continuous layer of adhesive, a patterned layer of adhesive, oran array of separate lines, spirals, or spots of adhesive. Adhesiveswhich have been found to be satisfactory are manufactured by FindleyAdhesives of Wauwautosa, Wisconsin, and marketed as Findley H2120. Theattachment means preferably comprises an open pattern network offilaments of adhesive as is disclosed in U.S. Pat. No. 4,573,986entitled “Disposable Waste-Containment Garment”, which issued toMinetola and Tucker on Mar. 4, 1986, and which is incorporated herein byreference. An exemplary attachment means of an open pattern network offilaments comprises several lines of adhesive filaments swirled into aspiral pattern such as is illustrated by the apparatus and methods shownin U.S. Pat. No 3,911,173 issued to Sprague, Jr. on Oct. 7, 1975; U.S.Pat. No. 4,785,996 issued to Ziecker, et al. on Nov. 22, 1978; and U.S.Pat. No. 4,842,666 issued to Werenicz on Jun. 27, 1989. Each of thesepatents are incorporated herein by reference. Alternatively, theattachment means may comprise heat bonds, pressure bonds, ultrasonicbonds, dynamic mechanical bonds, or any other suitable attachment mesasor combinations of these attachment means as are known in the ant.

The absorbent core 84 may be any absorbent means which is generallycompressible, conformable, non-irritating to the wearers skin, andcapable of absorbing and retaining liquids such as urine and othercertain body exudates. The absorbent core may be manufactured in avariety of sizes and shapes (e.g., rectangular, hour-glass, “T”-shaped,asymmetric, etc.) and from a wide variety of liquid absorbent materialscommonly used in disposable diapers and other absorbent articles such acomminuted wood pulp which is generally referred to as airfelt. Examplesof other suitable absorbent materials include creped cellulose wadding,meltblown polymers including coform, crosslinked cellulosic fibers,tissue including tissue wraps, absorbent foams, absorbent spongerssuperabsorbent polymers, absorbent gelling materials, or any Asequivalent materials or combinations of materials. The configuration andconstruction of the absorbent core may also be varied (e.g., theabsorbent core may have varying caliper zones, hydrophilic gradient,superabsorbent gradients, or lower average density and lower averagebasis weight acquisition zones; or may comprise one or more layers orstructures). The total absorbent capacity of the absorbent core should,however, be compatible with the design loading and the intended use ofthe pun-on diaper. Further, the size and absorbent capacity of theabsorbent core may be varied to accommodate wearers ranging from infantsthrough adults.

A preferred embodiment of the absorbent core has an asymmetric, modifiedhourglass shape and has a body surface toward the body of the wearer(inner surface) and a garment surface opposite the body surface. Anexemplary absorbent structure for use as the absorbent core of thepresent invention that has achieved wide acceptance and commercialsuccess is described in U.S. Pat. No. 5,360,420 entitled “AbsorbentStructures Containing Stiffened Fibs and Superabsorbent Materials”issued to Cook, Lash, Moore, & Young on Nov. 1, 1994. These referencesare incorporated herein by reference. Preferably, the absorbent corewill comprise an acquisition/distribution layer of chemically stiffenedcellulosic fibers and a storage layer positioned beneath theacquisition/distribution layer comprising a mixture of wood pulp fibersand superabsorbent material such as are disclosed in U.S. Pat. No.4,610,478 entitled “High-Density Absorbent Structures” issued to Weismanand Goldman on Sep. 9, 1986, and incorporated herein by reference.

The topsheet 80 is positioned adjacent the body surface of the absorbentcore 84 and is preferably joined to the absorbent core 84 and thechassis layer 40 by attachment means (not shown) such as those wellknown in the art. Suitable attachment means are described with respectto joining the absorbent core to the chassis layer. As used herein, theterm “joined” encompasses configurations whereby an element is directlysecured to the other element by affixing the element directly to theother element, and configurations whereby the element is indirectlysecured to the other element by affixing the element to intermediatemember(s) which in turn are affixed to the other element. In a preferredembodiment, the topsheet and the chassis layer are indirectly joinedtogether by directly joining them to the absorbent core or the elasticpanel members or other elements of the pull-on diaper.

The topsheet 80 preferably comprises a three member structure such asdisclosed in U.S. Pat. No. 4,795,454, entitled “Absorbent Article HavingLeakage-Resistant Dual Cuffs” issued to Dragoo on Jan. 3, 1989, which isincorporated herein by reference. As shown in FIG. 4, the topsheet 80comprises a primary layer 86 and barrier layers 88 joined to andextending laterally outwardly from the primary layer 86. The primarylayer 86 is a liquid pervious material allowing liquids to rapidlypenetrate through its thickness and be absorbed by the absorbent core.The two barrier layers 88 are preferably hydrophobic to prevent leakageout the sides of the diaper and are more preferably drawable tostrengthen the stretch laminates.

The primary layer 86 is preferably compliant, soft feeling, andnon-irritating to the wearer's skin. The primary layer is liquidpervious permitting liquids (e.g., urine) to readily penetrate throughits thickness. A suitable primary layer may be manufactured from a widerange of materials, such as porous foams; reticulated foams; aperturedplastic films or three dimensionally expanded formed films; or woven ornonwoven webs of natural fibers, synthetic fibers, or a combination ofnatural and synthetic fibers. Preferably, the primary layer ismanufactured by Fibertec, Inc. of Landisville, N.J. under thedesignation 6701.

In the embodiment shown in FIG. 3, the primary layer 86 is preferablynoncoterminous with the chassis layer so that liquid will not wick alongand through the primary layer to the edges of the pull-on diaper, sothat liquids will not wick underneath and beyond the stand-up barriercuffs formed by the barrier layers, and so that more drawable materialsmay be positioned in the side panels to produce stronger stretchlaminates. The primary layer preferably overlays a major portion of thebody surface of the absorbent core, more preferably all of the bodysurface area of the absorbent core in at least the crotch region, sothat exudates that are discharged into the pull-on diaper penetratethrough the primary layer where they are absorbed by the absorbent core.The primary layer extends laterally outwardly toward the side edges ofthe absorbent core, preferably beyond the side edges of the absorbentcore in at least the crotch region. The primary layer, however,terminates inwardly of the leg edges of the crotch region. In the mostpreferred configurations, the primary layer terminates adjacent theproximal edge of the barrier layer (i.e., the terminating edge of theprimary layer is positioned adjacent the proximal edge) or theterminating edge is positioned remotely from and inboard of the proximaledge. Adjacent is used in this context to mean that the primary layerterminates at the proximal edge plus or minus small areas of the primarylayer material that may extend inside or beyond the proximal edge due tomachine tolerances during manufacture or variations in the area of theprimary layer when it is manufactured.

In the preferred embodiment of the topsheet 80 shown in FIG. 3, thebarrier layers 83 form the elastic leg features 52 (preferably, agasketing cuff and/or a barrier cuff) and, preferably, a portion of thestretch laminates.

In order to form the gasketing/barrier cuff elastic leg feature as shownin FIG. 3, the barrier layer 88 preferably has a flap portion 90 and astand-up (channel) portion 92. The stand-up portion 92 has a proximaledge 95 and a distal edge 95′. While the flap portion 90 is preferably acontinuous segment of the barrier layer 88, the flap portion 90 may beformed from a different piece of material secured to the stand-upportion 92 so that the flap portion 90 could have different physicalproperties, dimensions, and characteristics than the stand-up portion92. In fact, the flap portion, or the stand-up portion, may be omittedentirely from the diaper if desired. The stand-up portion 92 forms anddefines the flap of the barrier cuff as described in U.S. Pat. No.4,795,454 (Dragoo). The proximal edge 95 of the stand-up portion ispreferably disposed between the elastic leg members 96 and thelongitudinal centerline, most preferably between the elastic leg members96 and the side edge of the absorbent core 84 in at least the crotchregion 30 to create a seal along the proximal edge. The distal edge 95′is preferably not secured to any underlying elements of the pull-ondiaper in at least the crotch region 30 to form the stand-up barriercuff. The ends of the stand-up portion are preferably joined to theunderlying structure of the pull-on diaper, the primary layer, byclosing means 98, such as any of the attachment means herein described,to enhance the stand-up function of the barrier cuffs. The stand-upportion 92 of the barrier layer 88 is thus preferably hydrophobic so asto reduce leakage of exudates from the pull-on diaper.

In a preferred embodiment of the present invention, at least somesegment of the flap portion 90 of the barrier layer 88 in the frontregion 26 and in the back region 28 is subjected to mechanicalstretching in order to provide the stretch laminates in the side panels64 and 64Γ, respectively. Thus, at least the flap portion 90, preferablythe entire barrier layer 88, is elongatable, more preferably drawable(but not necessarily elastomeric), so that the barrier layer will, uponmechanical stretching be at least to a degree permanently elongated suchthat it will not fully return to its original configuration. Inespecially preferred embodiments, the barrier layers can be subjected tomechanical stretching without undue rupturing or tearing. Thus, thebarrier layers are preferably elongatable, more preferably drawable, andmost preferably hydrophobic materials. Suitable materials for thebarrier layers include many of the layers suitable for the belt layers.A preferred material for the barrier layers comprises a spun-bondedpolyethylene or polyethylene blended fiber web. A suitable material forthe barrier layer is the spun-bonded polyethylene fiber web manufacturedby Fiberweb N.A. of Simpsonville, N.C. under the designation E1004203.

The pull-on diaper 20 can also preferably provided with vents orapertures to permit the passage of air and water vapor to and from theinterior of the pull-on diaper. In a preferred embodiment, the aperturesare positioned in the side panels. In this configuration, exudates areprevented from leaking out of the areas adjacent the absorbent core butair and water vapor are allowed to be exchanged in the product toventilate it so that the product does not become excessively wetted bybody perspiration and uncomfortable to wear. Vents may additionally beprovided in other panels of the pull-on product or on certain of thefeatures of the pull-on diaper. For example, vents may be provided inthe waistband panel in the front region or the back region to provideventilation and breathability in the waistband regions and/or vents maybe provided in the unitary waistcap/waistband to further enhanceventilation in the product.

The pull-on diaper would preferably have a plurality of vents within theside panels, the vents being arranged in a defined pattern of large andsmall apertures. The apertures are generally in the range of about0.3-2.5 mm in diameter, with the larger apertures being preferably inthe range of about 1-2 mm and the smaller apertures being in the rangeof about 0.5-0.9 mm in diameter. The apertures can be formed by punchingholes or apertures into the fabric or by forming holes by autogeneousbonds such as ultrasonic or thermal/pressure techniques. Such aperturesan forming techniques are described in U.S. Pat. No. 2,544,069 issued toCutler on Mar. 6, 1951; and U.S. Pat. No. 4,834,733 issued toKielpikowski et al. on May 30, 1989; each of which is incorporatedherein by reference. Preferably, the apertures extend through all of thelayers of the product, all of the layers of the stretch laminates in theside panels, such that the vents extend from the inside to the outsideof the product. Alternatively, the vents may only be made in one or moreof the layers or they may comprise slits or cuts rather than holes.

Breathability may alternatively be provided by making the materials ofthe pull-on diaper out of air or vapor permeable materials such as areknown in the at. For example, the chassis layer could comprise abreathable (vapor permeable) but liquid impervious plastic film. Theelastic panel members may be open material such as foams, scrims,nonwovens, or breathable elastomeric films to further enhance thebreathability of the pull-on diaper.

The pull-on diaper 20 of the present invention can be applied by acaregiver or be self-applied by the wearer. Typically, the waist opening36 will be expanded to allow the wearer to insert one of their feet intoone of the leg openings 34. The other foot is then inserted into theother leg opening 34. The pull-on diaper 20 is then pulled up over thetorso of the wearer into its wearing position. The force wall created bythe stretch laminates especially assists in self application of thepull-on diaper by forcing the product to be pulled up over the buttocksrather than further expanding. The pull-on diaper is then worn and cancontain and hold discharged body exudates. The pull-on diaper is removedfrom the wearer by either pulling it back down over the legs or tearingthe portions of the pull-on diaper adjacent the seams.

FIG. 5 shows a perspective crossectional view of an alternativeembodiment of the pull-on diaper of the present invention. As shown inFIG. 5, the chassis layer 540 forms the inner surface 24 of the pull-ondiaper 520. The chassis layer 540 thus serves as the topsheet. For thisreason, in this embodiment, the chassis layer 540 preferably comprises aliquid pervious nonwoven web. The chassis layer 540 is preferably thenonwoven material discussed previously herein with respect to theformation of the primary layer of the topsheet. The first belt layer 542is positioned adjacent the outer surface 577 of the chassis layer 540.The second belt layer (not shown) also is positioned adjacent the outersurface of the chassis layer. Additionally, a central backsheet layer510, preferably comprising a liquid impervious plastic film, ispositioned on the inner surface of the first belt layer 542, on theouter surface 577 of the chassis layer 40, so as to act as a backsheetfor the pull-on diaper. The elastic panel members 78 are positionedbetween the chassis layer 540 and the first belt layer 542 to form thefront stretch laminates. The absorbent core 84 is preferably positionedon the outer surface 577 of the chassis layer 540, preferably betweenthe chassis layer 540 and the central backsheet layer 510. The barriercuffs 514 of the elastic leg feature preferably comprise a relativelynarrow strip of material (a barrier flap) joined to the inner surface576 of the chassis layer 540 such as is shown in the above referencedU.S. Pat. No. 4,695,278 to Lawson. The flaps of the barrier cuff maycomprise a nonwoven web, a plastic film, or a laminate of a nonwoven weband a plastic film.

As shown in FIG. 5, the stretch laminates additionally comprise areinforcement layer 512 preferably positioned between the chassis layer540 and the elastic panel member 78. The reinforcement layer 512 acts to“strain reinforce” the stretch laminates to allow the deep mechanicalstretching (straining) of the stretch laminate without creating localtears or holes in the stretch laminate. As previously discussed, somematerials are more strainable than other materials, especially at thehigh straining forces encountered by the mechanical stretching operationdone on the stretch laminates. Thus, the joinder of a more strainablematerial with a less strainable material results in a combinationlaminate that will be strainable to such a high degree without unduetearing or ripping of the materials. This is especially important in thepresent embodiment where the chassis layer 540 comprises a nonwovenfabric. Since the chassis layer 540 acts as the topsheet for the pull-ondiaper 520, the chassis layer 540 will typically comprise a nonwovenmaterial which is readily liquid pervious but which is generally not asdrawable as other nonwoven materials. Thus, the chassis layer 540 ofthis embodiment will tend to shred or tear when it undergoes themechanical stretching operation to form the stretch laminates. Thereinforcing layer 512, which is a more drawable material than thechassis layer 540, when laminated to the chassis layer 540 prior tomechanical stretching bridges or spans the tears in the chassis layer540 to allow the overall stretch laminate to not fail or have holesduring use.

The reinforcing layer 512 may thus comprise a number of materials thatare drawable to provide the necessary strength in the stretch laminate.Examples of such reinforcing layers include plastic films, aperturedplastic films such as DRI-WEAVE marketed by The Procter & GambleCompany, or nonwoven webs. Preferably, in order to provide breathabilityin the stretch laminates, the reinforcing layer comprises an aperturedplastic film or a nonwoven material. More preferably, the reinforcinglayer comprises those nonwovens useful as the belt layers and describedherein.

As previously discussed, the reinforcing layers are preferablypositioned adjacent the weaker layers to provide them with strength. Inthe embodiment shown in FIG. 5, the reinforcing layer 512 is preferablypositioned on the outer surface 577 of the chassis layer 540 although itmay be positioned on the inner surface of the chassis layer 540 ifdesired. Additional reinforcement layers nay be provided in the stretchlaminates and positioned adjacent any of the elements thereof.

FIG. 6 shows an alternative embodiment of the pull-on diaper shown inFIG. 5. The chassis layer 640 functions as the topsheet. The first beltlayer 642 is positioned on the outer surface 677 of the chassis layer640, preferably directly adjacent the chassis layer 640 in the centralpanel. The elastic panel members 78 are positioned between the firstbelt layer 642 and the chassis layer 640 in the side panels. Thus, acontinuous belt is formed without intervening elements. Forces may thusbe distributed and transmitted continuously about the waist opening. Acentral backsheet layer 610 is positioned on the outer surface 612 ofthe first belt layer 642 and forms the outer surface 22 of the pull-ondiaper 620 in the crotch region and in the central panel of the frontregion and the back region. The absorbent core 84 is positioned betweenthe central backsheet layer 610 and the first belt layer 642. Since thefirst belt layer 642 extends over the surface of the absorbent core 84,the first belt layer 642 is also preferably liquid pervious. The firstbelt layer 642 may thus comprise the spun bonded polyethylene fibernonwoven material previously discussed herein; however, it is renderedsufficiently fluid pervious such as by adding a suitable surfactant. Oneor more reinforcement layers may also be positioned in the side panelsto prevent undue ripping or tearing of both the chassis layer 640 andthe first belt layer 642.

FIG. 7 is a perspective cross-sectional view of a further alternativeembodiment of the pull-on diaper shown in FIG. 5. In this embodiment,the absorbent core 84 is positioned between the chassis layer 740 andthe first belt layer 742. Since the first belt layer 742 need not beliquid pervious since it is positioned on the garment surface of theabsorbent core 84, the first belt layer 742 is preferably drawable andcomprises the materials previously described herein for use as the beltlayers. The central backsheet layer 710 is positioned on the outersurface 712 of the first belt layer 742 to form the outer surface 22 ofthe pull-on diaper 720 in the crotch region and in the central panel ofthe front region and the back region. A reinforcement layer (not shown)may also be positioned between the chassis layer 740 and the elasticpanel member 78 to reinforce the chassis layer 740.

FIG. 8 is a cross-sectional view of an alternative barrier cuffconfiguration of the present invention. As shown in FIG. 8, the flap ofthe barrier cuff 810 comprises the stand-up portion 892 of the barrierlayer 88. The barrier cuff 310 has a proximal edge 895 and a distal edge812. The proximal edge 895 is joined to the side layer 840 to provide aseal to prevent wicking and leaking of exudates out of the side of theleg openings. The distal edge 812 is formed by folding a portion of thebarrier layer 83 onto itself and around the elastic spacing members 94.The elastic spacing members 94 are operatively joined to the flap, thebarrier layer 88, in an elastically contractible condition adjacent saiddistal edge 812 to cause the distal edge 812 to stand-up away from theprimary layer 86. A containment layer 814 is joined to the flap, thebarrier layer 88. The containment layer 814 is preferably a liquidimpervious film to further prevent leakage through the barrier cuff 810.The containment layer 814 preferably comprises a polyethylene film. Thecontainment layer 814 preferably extends from just laterally outwardlybeyond the proximal edge 895 to a point intermediate the proximal edge895 and the distal edge 812. In the embodiment shown in FIG. 8, thecontainment layer is positioned between the folded over portions of theflap. The containment layer 814 extends beyond the proximal edge 895 tofurther provide an impermeable seal at the proximal edge 895. Thecontainment layer 814 preferably does not extend to the distal edge 812(in this embodiment—about 6.35 mm (about 0.25 in) from the distal edge)to provide a breathable portion adjacent the distal edge 812 to maintaingood skin health. Thus, the barrier cuff 810 is liquid and gasimpervious at the base of the barrier cuff 810 to prevent leakage whilebeing gas pervious adjacent the distal edge 812 to enhance the softnessand breathability of the barrier cuff 810.

A secondary “barrier” is created by a second elastic spacing member 894operatively joined with said flap intermediate said proximal edge andsaid distal edge, preferably at least about 12.5 mm (about 0.5 in) fromthe elastic spacing members 94. The second elastic spacing member 894 ispreferably joined to the flap between the flap and the containment layer814. Since the containment layer is most preferably joined to the flapat spaced apart zones (adjacent the proximal edge 895 and adjacent thefolded over portion of the flap) such that an intermediate portion ofthe containment layer is unsecured to the flap, the second elasticspacing member is preferably joined to the flap adjacent thisintermediate portion such that the second spacing elastic member tendsto space the flap away from the containment layer 814 to form a pocket.The second elastic spacing member 894 thus provides a more breathablesection of flap adjacent the body since only the nonwoven flap contactsthe body. The second elastic spacing member 894 is preferablyoperatively joined with the flap at a lower force than the elasticspacing members 94 so as to not affect the functionality of the elasticspacing member 94 but to space the flap away from the containment layer814. The second elastic spacing member 894 is operatively joined in anelastically contractible condition, preferably being secured onlyadjacent its ends such than an intermediate portion is unsecured to theflap (i.e., it is secured in a manner to form a drawstring elastic as sdeed in U.S. Pat. No. 4,816,025 entitled “Disposable Diaper Having AnImproved Leg Conforming Cuff” issued to Richardson on Mar. 28, 1989,which is incorporated herein by reference) to allow the second spacingelastic member 894 to float within the flap, within the space defined bythe flap and the containment layer, so as to provide softness andflexibility as well as better breathability/skin health by spacing thebreathable nonwoven flap away from the containment layer and contact thebody.

As a further preferred embodiment to the above barrier cuff embodiment,the cuff height and spacing of the barrier cuff may be adjusted by theway the barrier cuffs are joined to the pull-on diaper. FIG. 8A showshow the barrier cuff 810 nay be joined to the topsheet 80 to optimizethe cuff height and cuff spacing. The inner surface of the flap isjoined to the diaper, typically the topsheet 80, at its ends laterallyinward from the proximal edge by a first closing means 816 at about halfthe cuff height (adjacent the second elastic spacing member 894). Thedistal edge 812 is then folded laterally outward back toward theproximal edge such that a first barrier segment 820 and a second barriersegment 822 is formed The outer surface of the flap in the secondbarrier segment 822 is joined to the outer surface of the flap in thefirst barrier segment 820 at the ends of the flap by a second dosingmeans 818. The fold provides a wider cuff spacing and a taller cuffheight in the crotch region 30 to significantly improve leakageperformance (especially BM containment). It should be noted that thelocation of the second closing means 818 along the segments can bevaried to vary the cuff height and cuff spacing. The cuff height is aparticularly important parameter for pull-on garments since the barriercuff may cause difficulty in application since the wearer's foot may getcaught on it. The cuff height is preferably less than about 44.5 mm(about 1.75 in), more preferably between about 31.75 mm and about 44.5mm (about 1.25 in to about 1.75 in) with the cuff spacing in the crotchregion 30 being from about 63.5 mm (about 2.5 in) to about 90 mm (about3.5 in).

FIG. 9 shows an alternative embodiment of the present invention in whichvents 54 are provided in the side panels and a portion of the chassislayer 940 has been removed (“windowed”) in each waistband pane. Thisportion of the chassis layer has been removed in order to provideenhanced breathability in the waistband panels 60 and 60′. The belt inthe waistband panels thus comprises the respective belt layer (firstbelt layer 42 or second belt layer 44), the primary layer 86 of thetopsheet 80, and in certain segments the unitary waistcap/waistband 82.Since the belt layer and the primary layer of the topsheet are bothpreferably nonwoven webs, water vapor will be allowed to pass been theinterior and exterior of the pull-on diaper, thereby enhancing theoverall breathability of the pull-on diaper. The vents 54 are similar tothose previously described herein and provide enhanced breathability inthe side panels.

FIG. 10 shows a still further alternative embodiment of the pull-ondiaper of the present invention. The chassis layer 1040 also serves asthe belt layers. The chassis layer 1040 also provides the outer surface22 of the pull-on diaper 1020 in both the front region, the back region,and the crotch region. In this embodiment, the chassis layer 1040preferably comprises a nonwoven web to give the overall pull-on diaperthe feel and appearance of a cloth garment. The topsheet 80 comprises aprimary layer 86 and a pair of barrier layers 88. In this embodiment,the pull-on diaper 1020 is provided with a composite backsheet that actsas the backsheet for the absorbent core 84 and as reinforcement layersfor the stretch laminates in the side panels. In this embodiment, thebacksheet comprises a central backsheet layer 1002 and a pair ofbacksheet reinforcement layers 1004. The central backsheet layer 1002 ispreferably a liquid impervious film to contain exudates within theabsorbent core 84. However, since the central backsheet layer 1002 neednot be subjected to mechanical stretching, it can comprises the liquidimpervious, vapor pervious films such as previously described herein togive the product overall breathability in the crotch region and thecentral panels of the front region and the back region. Since thebacksheet reinforcement panels 1004 are subjected to mechanicalstretching, they preferably comprise any of the materials suitable foruse as a reinforcement layer as previously described herein includingnonwoven webs or plastic films. In the embodiment illustrated, thebacksheet reinforcement layers 1004 comprise a plastic film such as isused as the chassis layer for the embodiments of FIGS. 1-4. Although itis preferred that the backsheet reinforcement layers overlap with and,more preferably are joined to, the central backsheet layer, thebacksheet reinforcement layers may alternatively be spaced laterallyoutward from and not be secured to the central backsheet layer such thatthe backsheet reinforcement layers act as independent reinforcementlayers. Since both the central backsheet layer 1002 and the backsheetreinforcement layers 1004 preferably each comprise a plastic film, thelayers may be joined together prior to being combined into the pull-ondiaper for ease of handling during manufacture. The elastic panelmembers 78 are preferably positioned between the chassis layer 1040 andthe backsheet reinforcement layer 1004 to provide the stretch laminates.

While particular embodiments of the present invention have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications can be made withoutdeparting from the spirit and scope of the invention. It is thereforeintended to cover in the appended claims all such changes andmodifications that are within the scope of this invention.

What is claimed is:
 1. A unitary disposable pull-on garment comprising:(a) a chassis defining (i) a front region having an end edge, sideedges, leg edges, central panel comprising a waistband panel and amedial panel, side panels extending laterally outwardly from saidcentral panel, and a seam panel extending laterally outwardly from eachsaid side panel to said side edge, said seam panels and said side panelsextending longitudinally from said end edge to said leg edge; (ii) aback region opposed to said front region, said back region having an endedge, side edges, leg edges, a central panel comprising a waistbandpanel and medial panel, side panels extending laterally outwardly fromsaid central panel to said side edge, and a seam panel extendinglaterally outwardly from each said side panel to said side edge, saidseam panels and said side panels extending longitudinally from said endedge to said leg edge; and (iii) a crotch region between said frontregion and said back region; said chassis having an outer surface and aninner surface; (b) a backsheet having an outer surface and an innersurface opposite said outer surface; (c) an absorbent core positioned onsaid inner surface of said backsheet, said absorbent core having agarment-facing surface and a wearer-facing surface; (d) a liquidpervious topsheet positioned on said wearer-facing surface of saidabsorbent core; (e) an elastically extensible front stretch laminatepositioned in, each said side panel of said front region, each saidfront stretch laminate being elastically extensible in at least thelateral direction; (f) an elastically extensible-back stretch laminatepositioned in each said side panel of said back region, each said backstretch laminate being elastically extensible in at least the lateraldirection; each said back stretch laminate and said front stretchlaminate having: (i) an initial pull extension force between about 150grams/in to about 225 grams/in at 100% extension when subjected to aninitial extension at a rate. of 50.8 cm/min at about 23° C.; and (ii) asecond cycle recovery force between about 25 grams/in and about 200grams/in at 20% to 140% extension when subjected to twoextension/recovery cycles at an initial extension at a rate of 50.8cm/min at about 23° C., held for 30 seconds at 200% extension, relaxedat the same rate, remain unconstrained for one minute, and thenrepeating at the same rate and conditions; and (g) seams joining saidfront region to said back region adjacent said side edges in said seampanel so as to form two leg openings and a waist opening.
 2. The garmentof claim 1 wherein said initial pull extension force is between about200 grams/in to about 400 grams/in at 200% extension.
 3. The garment ofclaim 1 or 2 wherein said second cycle recovery force is between about60 grams/in and about 150 grams/in at 20% to 140% extension.
 4. Thegarment of claim 3 wherein said initial pull extension forces is betweenabout 160 grams/in and about 200 grams/in at 100% extension.
 5. Thegarment of claim 4 wherein each said front stretch laminate and saidsecond stretch laminate has an available stretch of between about 100%and about 250%.
 6. The garment of claim 5 wherein each said frontstretch laminate and said second stretch laminate has an force wallwherein an incremental increase of 50% or less extension above 200%extension produces a force greater than 400 grams/in.
 7. A unitarydisposable pull-on garment comprising: (a) a chassis layer comprising acontinuous sheet defining (i) a front region having an end edge, sideedges, leg edges, a central panel comprising a waistband panel and amedial panel, side panels extending laterally outwardly from saidcentral panel, and a seam panel extending laterally outwardly from eachsaid side panel to said side edge, said seam panels and said side panelsextending longitudinally from said end edge to said leg edge; (ii) aback region opposed to said front region, said back region having an endedge, side edges, leg edges, a central panel comprising a waistbandpanel and medial panel, side panels extending laterally outwardly fromsaid central panel to said side edge, and a seam panel extendinglaterally outwardly from each said side panel to said side edge, saidseam panels and said side panels extending longitudinally from said endedge to said leg edge; and (iii) a crotch region between said frontregion and said back region; said chassis layer having an outer surfaceand an inner surface; (b) a backsheet positioned on said inner surfaceof said chassis layer, said backsheet having an outer surface adjacentsaid inner surface of said chassis layer and an inner surface oppositesaid outer surface; (c) an absorbent core positioned on said innersurface of said backsheet, said absorbent core having a garment-facingsurface and a wearer-facing surface; (d) a liquid pervious topsheetpositioned on said wearer-facing surface of said absorbent core; (e) anelastically extensible front stretch laminate positioned in each saidside panel of said front region, each said front stretch laminatecomprising a portion of said chassis layer in said side panel and anelastic panel member operatively joined with said chassis layer, eachsaid front stretch laminate being elastically extensible in at least thelateral direction; (f) an elastically extensible back stretch laminatepositioned in each said side panel of said back region, each said backstretch laminate comprising a portion of said chassis layer in said sidepanel, and an elastic panel member operatively joined with said chassislayer, each said back stretch laminate being elastically extensible inat least the lateral direction; each said back stretch laminate and saidfront stretch laminate having: (g) seams joining said front region tosaid back region adjacent said side edges in said seam panel so as toform two leg openings and a waist opening.
 8. The garment of claim 1wherein said initial pull extension force is between about 200 grams/into about 400 grams/in at 200% extension.
 9. The garment of claim 8wherein said second cycle recovery force is between about 60 grams/inand about 150 grams/in at 20% to 140% extension.
 10. The garment ofclaim 9 wherein said initial pull extension force is between about 160grams/in and about 200 grams/in at 100% extension.
 11. The garment ofclaim 10 wherein each said front stretch laminate and said secondstretch laminate has an available stretch of between about 100% andabout 250%.
 12. The garment of claim 11 wherein each said front stretchlaminate and said second stretch laminate has a force wall wherein anincremental increase of 50% or less extension above 200% extensionproduces a force greater than 400 grams/in.